MagIron Plans 2 Million Tonne US Merchant Pig Iron Project

US-based MagIron is advancing plans to establish large-scale domestic merchant pig iron production with an annual capacity of approximately 2 million tonnes, potentially strengthening the US steel industry’s raw material supply chain. A concept and economic study completed by Primetals Technologies assessed three production routes, including MIDREX Flex direct reduction combined with electric smelting, electric arc furnace processing, and conventional blast furnace production. All three options were found to be technically viable. MagIron plans to utilise its existing mining, processing, pelletising and logistics infrastructure in Minnesota and Indiana, helping reduce the need for entirely new supply networks. Following a final investment decision, initial commissioning and first hot metal production could begin within two to three years. The project could significantly reduce US dependence on imported merchant pig iron. The country currently imports almost all of its requirements, with annual consumption historically ranging between 4 million and 6 million tonnes. At its proposed capacity, MagIron could potentially supply around one-third to one-half of US merchant pig iron demand. The company also plans to retain flexibility to produce direct reduction-grade iron ore pellets based on customer requirements and market conditions.